Manual 8557989

Transcript

TK 55186-2-IM (Rev. 0, 09/11) Trailer Edition HK-430 and HK-430 HO Diesel Heating Units Installation Manual Providing equipment and services to manage controlled-temperature environments for food and other temperature-sensitive products, our Climate Control Technologies sector encompasses both transport and stationary refrigeration solutions. Our product brands include Thermo King®, a world leader in transport temperature control systems, and Hussmann®, a manufacturer of refrigeration and food merchandising equipment. www.thermoking.com www.hussmann.com www.ingersollrand.com ©2008 Ingersoll-Rand Company Printed in U.S.A. on Recycled Paper Installation Manual Trailer Edition HK-430 and HK-430 HO Diesel Heating Units TK 55186-2-IM (Rev. 0, 09/11) Copyright© 2011 Thermo King Corp., Minneapolis, MN, U.S.A. Printed in U.S.A. Release History Released Rev. 0, 09/11 2 Introduction This installation manual was written to assist with the installation of the Thermo King HK-430 and HK-430 HO diesel heating units onto trailers or intermodal containers specifically designed and built for these applications. Due to its complexity, you should not attempt this installation unless you: • Are an experienced mechanic • Can safely lift 34 kilos (75 lbs.) • Are certified or trained in the repair and maintenance of diesel powered refrigeration systems • Have a basic understanding of electricity and electrical wiring • Have the necessary tools and equipment to complete the installation. This manual is published for informational purposes only. Thermo King makes no representations warranties express or implied, with respect to the information recommendations and descriptions contained herein. Information provided should not be regarded as all-inclusive or covering all contingencies. If further information is required, Thermo King Corporation Service Department should be consulted. Thermo King’s warranty shall not apply to any equipment which has been “so installed, maintained, repaired or altered as, in the manufacturer’s judgment, to affect its integrity.” Manufacturer shall have no liability to any person or entity for any personal injury, property damage or any other direct, indirect, special, or consequential damages whatsoever, arising out of the use of this manual or any information, recommendations or descriptions contained herein. 3 Table of Contents Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Group 31 Battery Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Required Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Uncrating and Installing the Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Installation Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Installing the Remote HMI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Trailer / Container Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Installing the Fuel Tank - Aluminum, 22'' dia. 30 & 50 Gallon - (Option) 24 Mounting Bolt Specifications and Installation Requirements . . . . . . . . . 12 Installing the Fuel Tank - Aluminum, L-Shaped, 65 Gallon - (Option) . 28 Unit Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Installing the Fuel Tank - Steel, Rectangle, 65 Gallon - (Option) . . . . . 32 HMI Remote Mount Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Installing the Fuel Pump and Fuel Lines . . . . . . . . . . . . . . . . . . . . . . . . . 36 Status Light Dimensions (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Installing the Remote Status Light - (Option) . . . . . . . . . . . . . . . . . . . . . 40 Flush Mount Status Light Opening Dimensions (Option) . . . . . . . . . . . . 17 Installing the Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Battery Selection Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 SYSTEM CHECK LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 4 Safety Precautions The symbol appears next to a point that is particularly important: DANGER: Addresses a circumstance that, if encountered, will lead to death or serious injury WARNING: Addresses a circumstance that, if encountered, might lead to death or serious injury. CAUTION: Addresses a circumstance that, if encountered, may cause damage to equipment or minor injury. WARNING: Keep your hands away from fans and belts when the unit is running. Set all electrical controls to the OFF position before servicing the unit. WARNING: Make sure all mounting bolts are tight and are of correct length for their particular application WARNING: When using ladders to install or service refrigeration systems, always observe the ladder manufacturer’s safety labels and warnings. A work platform is the recommended method for installations. CAUTION: Exposed coil fins are very sharp and can cause painful lacerations.Wear leather work gloves to prevent injury. WARNING: Never drill holes in the unit unless absolutely necessary. Holes drilled into the unit may weaken structural components. Holes drilled into electrical wiring can cause fire or explosion. 5 Safety Precautions (continued) Battery Installation and Cable Routing WARNING: Improperly installed battery could result in a fire or explosion! A Thermo King approved battery must be installed and properly secured to the battery tray. WARNING: Improperly installed battery cables could result in fire or explosion! Battery cables must be installed, routed and secured properly to prevent them from rubbing, chaffing or making contact with hot, sharp or rotating components. WARNING: Do not attach fuel lines or any additional wiring harnesses to the battery cables as this could cause an electrical fire! CAUTION: Do not connect other manufacturer’s equipment or accessories to the Thermo King unit. This could result in severe damage to equipment and void the warranty! CAUTION: Set all unit electrical controls to the OFF position before connecting battery cables to the battery to prevent unit from starting unexpectedly and causing personal injury. CAUTION: Always wear protective clothing, gloves and eye wear when handling and installing batteries. Battery acid can cause serious burns when exposed to eyes or skin. If battery acid contacts skin or clothing, wash immediately with soap and water. If acid enters your eye, immediately flood it with running cold water for at least twenty minutes and get medical attention immediately. CAUTION: Always cover battery terminals to prevent them from making contact with metal components during battery installation. Battery terminals grounding against metal could cause the battery to explode. 6 Required Tools 1. Safety Glasses 2. Drill 3. Drill Bits 4. Tape Measure 5. Mechanics Tools 6. Lifting Device 7. Two Forged Eyebolts (1/2-13 UNC) 8. Work Platform (Recommended) 9. Torque Wrench NOTE: Equipment such as torque wrenches should be in good working condition and routinely calibrated to assure accurate readings. 7 Installation Components HARDWARE KIT FUEL LINE KIT FUEL PUMP KIT Clamps Hose 1/4 OD x 40 ft. Fuel Pump Bandwraps Hose 3/8 OD x 40 ft. Hose Fitting 3/8'' Screw 1/4-20 SS Eyelet fitting 1/4'' Pump Bracket Nut 1/4-20 SS Eyelet Fitting 3/8'' Harness Nut 1/2-13 Sleeve Fitting 1/4'' Nameplate Washer 1/2- SAE Sleeve Fitting 3/8'' Washer 1/4 SS Nut Fitting 1/4'' Washer 1.25 OD Nut Fitting 3/8'' Screw #10 Connector 1/4'' Screw 1/4-20 Connector Fuel Line Screw Torx T-25 Hose 4.00 in. long 8 BLANK PAGE 9 Trailer / Container Requirements Front Wall Mounted Fuel Tank HK-430 and HK-430 HO DANGER: The front wall of the trailer or container must be structurally strong enough to support the weight of the HK 430 or HK-430 HO unit! IMPORTANT: Thermo King HK-430 and HK-430 HO diesel heating units should only be installed onto trailers or containers specifically designed and built for these applications. WEIGHTS* Thermo King HK unit with EON battery installed. HK-430 HK-430 HO 203 kg (448 lbs.) 221 kg (488 lbs.) DANGER: The front wall of the trailer or container must be structurally strong enough to support the weight of the HK-430 or HK-430 HO unit and the 65 gallon fuel tank! - DANGER: An improperly installed fuel tank could lead to serious injury or death! Consult your trailer or container manufacturer for specific details on proper fuel tank installation and recommendations. IMPORTANT: Thermo King HK-430 and HK-430 HO diesel heating units should only be installed onto trailers or containers specifically designed and built for these applications. * Does not include weight of fuel, fuel tank and brackets. 10 Trailer / Container Requirements 11 Mounting Bolt Specifications and Installation Requirements Mounting Bolts Specifications Mounting Bolt Installation Requirements DANGER: The use of mounting bolts other than those specified could result in severe damage to equipment, void the warranty or cause personal injury or death! DANGER: Four mounting bolts must be installed to properly secure the unit to the trailer front wall! Failure to do so could result in severe damage to equipment, void the warranty or cause personal injury or death! NOTE: Mounting hardware to be supplied by installer. • Use Metric M12 x 1.75 pitch class 8.8 (1/2 in.-13 UNC - 2B Rolled thread grade 5), medium carbon steel bolts and locking nuts. • All hardware must be zinc plated with dichromate finish. NOTE: The location of the unit mounting bolts in the trailer front wall is critical to proper unit installation. • A gasket sealing surface of 76.2 mm (3.00 in.) wide all around the trailer wall opening must be free from rivets or bolt heads and flat within 6.5 mm (.25 in.) • All mounting bolts must be square with the front wall and securely fastened to the trailer wall in such a manner to allow the mounting nuts be torqued to 82 N•m (60 ft. lbs.) from outside the trailer. • Mounting bolts are to extend 57.2 mm (2.25 in.) beyond the front wall (Detail I). • Surface of all mounting bolts are to be flat within 2.5 mm (0.10 in.). 12 Mounting Bolt Specifications and Installation Requirements 13 Unit Dimensions 14 HMI Remote Mount Dimensions 15 Status Light Dimensions (Option) Corner Mount Version Surface Mount Version 16 Flush Mount Status Light Opening Dimensions (Option) NOTE: Dimensions shown will accommodate the Surface Mount Standard Display version only. 17 Battery Selection Guide Refer to Service Bulletin T&T 446 for more information regarding Battery Selection and Maintenance. CAUTION: Do not connect other manufacturer’s equipment or accessories to the Thermo King unit! This could result in severe damage to equipment and void the warranty! IMPORTANT: The specified battery, electrical wiring and electronic controls were designed to operate and maintain only the Thermo King refrigeration system and factory authorized Thermo King options. Trailer units are designed for one 12 volt, Group 31 battery supplied by the installer. The battery must be suitable for deep cycling, heavy duty and rated with a minimum of 95 amp/hr. NOTE: See following table for Thermo King approved batteries. Refer to Service Bulletin T&T 446 for more information regarding Battery Selection and Maintenance. BATTERY APPLICATION TABLE 750 CCA Wet Cell Thermo King ReliaMax 750S P/N 203-731 Threaded Stud P/N 203-730 SAE Post 925 CCA Wet Cell Thermo King ReliaMax 925N P/N 203-733 Threaded Stud P/N 203-732 SAE Post 1150 CCA Dry Cell (AGM) Thermo King EON P/N 203-550 Threaded Stud P/N 203-551 SAE Post • Wet Cell Technology • Better suited for warmer climates • Less cranking power at low ambient temperatures • 18-24 month expected life *see note below • Choose for southern climates • Wet Cell Technology • Better suited for colder climates • High cranking power at low ambient temperatures • 18-24 month expected life *see note below • Choose for northern climates • Dry Cell (AGM) Technology • Better suited for all applications • High cranking power at lower ambient temperatures • Suited for extreme temperatures • Best for high cycling applications (Cycle-Sentry use) • 5-7 year expected life * NOTE: Wet cell battery life and maintenance requirements are determined by the operating environment and the charge/discharge rate (cycles) while the battery is in service. Higher ambient temperatures and frequent discharges will shorten a wet cell battery’s overall life expectancy and increase maintenance requirements. 18 Group 31 Battery Dimensions Lug Connections Threaded Stud Connections 19 Uncrating and Installing the Unit Uncrating the Unit DANGER: Do not use a forklift to install the unit! This could result in severe damage to the equipment, void the warranty or cause personal injury or death! WARNING: Use only locking hooks to safely lift the unit! Failure to use locking hooks could result in severe damage to the equipment, void the warranty or cause personal injury or death! (Detail I). To avoid unnecessary damage to your unit, place the crated unit near the trailer prior to its removal. 1. Carefully remove top boards of the crate. 2. Remove installation kit boxes and any other loose components from rear of unit. 3. Attach two forged lifting eyebolts (1/2-13 UNC) into the thread holes located on top of unit (Detail I). 4. Attach lifting device to eyebolts and slightly raise unit. 5. Remove hardware holding unit to crate. Installing the Unit Optional Zero Cube Installation A zero cube installation kit is available from your Thermo King Dealer. The kit consists of a insulated collar that positions the HK unit outside the cargo area of the trailer. 6. Loosen each lifting plate bolt located on the collar, rotate the lifting plates 180 degrees and retighten bolts. 7. Attach a lifting device to the lifting plates and raise the collar into position at the rear of the unit with the gasket surface facing the trailer opening. 8. Secure the collar to the rear of the unit with appropriate hardware and tighten securely. 9. Unbolt and remove the lifting plates from the collar. Reinstall only the bolts onto the collar. 10. Continue by following steps #11-15 below. Standard Unit Installation 11. Lift the HK unit and position it in the trailer opening. 12. With the HK unit access door open, align the four mounting holes with the mounting bolts. 13. Attach washer and elastic stop nuts (Nylock) and torque to 82 N•m (60 ft. lbs.). 14. Route the drain hose straight down and past the bottom of the trailer and secure with supplied clamps and screws. Be sure not to pinch the drain hose closed when routing and installing clamps. 15. See “Installing the Remote HMI” on page 22. 20 Uncrating and Installing the Unit 21 Installing the Remote HMI NOTE: The installation views shown are for reference only. The actual locations chosen for installing the remote HMI may vary per your specific application and should not interfere with the operation of the trailer or container. Surface Mount Installation Flush Mount Installation 1. Position the HMI onto the surface of the front wall while providing a drip loop as shown. NOTE: Installer to provide a recessed pocket in the trailer wall to accommodate the remote HMI. This recessed pocket must be deep enough to help protect the HMI from damage and allow for water drainage. See “HMI Remote Mount Dimensions” on page 15. 2. Open the front cover to access the four mounting holes. • Secure to the trailer wall with the supplied T-25 Torx head self tapping screws. IMPORTANT: Do not overtighten the screws or the plastic enclosure will be damaged. 3. Secure the harness to the trailer wall with the supplied clamps and self tapping screws. 1. Position the HMI into the recessed pocket while providing a drip loop as shown. 2. Open the front cover to access the four mounting holes. • Secure to the recessed pocket with the supplied T-25 Torx head self tapping screws. IMPORTANT: Do not overtighten the screws or the plastic enclosure will be damaged. 3. Secure the harness to the trailer wall with the supplied clamps and self tapping screws. 22 Installing the Remote HMI Surface Mount Installation Flush Mount Installation Recessed pocket shown (installer provided) 23 Installing the Fuel Tank - Aluminum, 22'' dia. 30 & 50 Gallon - (Option) Installed onto Trailers with Standard Cross Member Spacing DANGER: An improperly installed fuel tank could lead to serious injury or death! Consult your trailer manufacturer for specific details on proper fuel tank installation and recommendations. CAUTION: The trailers crossmembers must be strong enough to safely support the combined weight of the mounting hardware, fuel tank and fuel. Fuel Tank Capacity Combined Total Weight 30 Gallon Diesel 142 KG (313 lbs.) 50 Gallon Diesel 214 KG (471 lbs.) Open Style Tank Mounting Bracket - New fuel tank mounting kits were released November 1, 2008. Factory Kit 701635 and Aftermarket Kit 90-398 contain a new open style fuel tank mounting bracket. This new mounting bracket can be used to install either a 30 or 50 gallon, 22'' diameter fuel tanks onto a typical trailer with standard crossmember spacing of 6'', 8'', 10'' or 12''. • Trailers with non-standard crossmember spacing of 9'', 15'' and 16'' will require the additional components found in Kit 701658 (90-399) to complete the installation. • These new kits can not be used to install a 75, 90, 110 or 120 gallon, 22'' diameter fuel tanks. Those tanks require Kit 710278 (90-121). • DO NOT substitute any components from Kits 701635 (90-398) and 701658 (90-399) with any previously supplied fuel tank mounting kits as they are not interchangeable. • A. Fuel Tank Position • Thermo King recommends the fuel tank be mounted 203.2 mm (8.00 in.) under the trailer as shown. Otherwise, the OEM or installer is responsible to ensure the fuel tank position meets or exceeds DOT or Federal Highway regulations, when applicable. B. Tank Strap Position • 30 Gallon Tanks - Fuel tank straps must be positioned 381 mm (15.00 in.) apart as shown. • 50 Gallon Tanks - Fuel tank straps must be positioned 673 mm (25.50 in.) apart as shown. C. Rubber Strips and Pads • Rubber strips must be properly installed on both the mounting bands and the rubber pads must be installed onto the underside of the hanger assemblies to prevent metal to aluminum contact. D. Mounting Hardware • Grade 5 mounting hardware is supplied. Substitutions are not acceptable! • All mounting hardware must be properly installed and torqued to the specifications listed. Hardware Size Torque Specifications 3/8-16 Grade 5 42 N•m (31 ft-lb) 1/2 -13 Grade 5 81 to 88 N•m (60-65 ft-lb) 1/2'' T-bolts 48 N•m (35 ft-lb.) Kits 701635 (90-398) and 701658 (90-399) are specifically designed to install a 30 or 50 gallon fuel tank in a hanging position under a trailer attached to the floor crossmembers. Substitutions are not acceptable! 24 Installing the Fuel Tank - Aluminum, 22'' dia. 30 & 50 Gallon - (Option) Standard crossmember spacing shown. For other crossmember spacing, refer to TK-54238-2-IM. Non-standard crossmember spacing of 9'', 15'' and 16'' also requires Kit 701658 (90-399) Cross Member Spacing NOTE: Location of mounting holes may change if other trailer options are added. Tank can be mounted on either side of trailer. 50 Gallon Fuel Tank Shown 25 Installing the Fuel Tank - Aluminum, 22'' dia. 30 & 50 Gallon - (Option) Fuel Tank Installation NOTE: Location of mounting holes may change if other trailer options are added. 1. Locate the existing sets of 10.3 mm (.406'' dia.) pre-punched holes in the crossmembers. See note above. 2. Align the two holes of each hanger bracket with the holes in the crossmember and secure with two, 3/8-16 screws, washers and locking nuts. Torque the hardware to 42 N•m (31 ft-lb). 3. Install each hanger assembly (facing each other as shown) onto the hanger brackets with 1/2-13 screws, washers and locking nuts. Torque the hardware to 81 to 88 N•m (60-65 ft-lb). 4. Clean the underside of each hanger assembly and install the selfadhesive rubber pads. 5. Loosely install the tank straps t-bolts onto the hanger assemblies with 1/2'' washers and locking nuts. Verify the rubber strips are properly installed on the mounting bands. 6. Install the fuel tank into the straps with the tank positioned vertically within plus or minus 5 degrees and tighten the tank straps to 48 N•m (35 ft-lb). 26 Installing the Fuel Tank - Aluminum, 22'' dia. 30 & 50 Gallon - (Option) Open Style Bracket Orient Tank Vertically NOTE: Location of mounting holes may change if other trailer options are added. 27 Installing the Fuel Tank - Aluminum, L-Shaped, 65 Gallon - (Option) Important Fuel Tank Installation Information NOTE: These instructions are written exclusively for, and are limited to, the installation of the aluminum L-Shaped 65 gallon fuel tank, positioned directly under a Thermo King HK heating unit, and mounted onto the front wall of a trailer or intermodal container designed specifically for this application. All other installations are the responsibilities of the installer. DANGER: An improperly installed fuel tank could lead to serious injury or death! The mounting hardware to secure the fuel tank and mounting brackets onto the front wall of the trailer or intermodal container is to be supplied by the installer and must be 1/2-13 UNC (rolled thread), Medium Carbon Steel (Grade 5 or better) with Zinc Plate and Dichromate finish. Additionally, the front wall of the trailer or intermodal container must be structurally strong enough to safely support the combined total weight of the HK heating unit, the fuel tank and mounting brackets and 65 gallons of diesel fuel (see chart below). Consult your trailer or intermodal container manufacturer for details regarding your specific installation. A. FUEL TANK POSITION • B. TANK STRAP POSITION • Fuel tank mounting brackets and support straps must be positioned 1225 mm (48.25 in.) apart to properly support the weight of the tank and fuel. • The tank straps must fit into the strap guides located on the top of the fuel tank. C. RUBBER STRIPS AND PADS • HK-430 HK-430 HO 203 kg (448 lbs.) 221 kg (488 lbs.) L-shaped fuel tank, mounting brackets and hardware. 53.5 kg (118 lbs.) 53.5 kg (118 lbs.) 65 gallons of diesel fuel. 236 kg (520 lbs.) 236 kg (520 lbs.) 447 kg (986 lbs.) 511 kg (1126 lbs.) COMBINED TOTAL WEIGHT Rubber strips must be properly installed on the mounting brackets, and mounting bands to prevent metal to aluminum contact. D. MOUNTING HARDWARE • Grade 5 mounting hardware is supplied to secure the tank to the mounting brackets. • Mounting hardware to secure the complete fuel tank and mounting bracket assembly onto the trailer or container is to be supplied by the installer and must be 1/2-13 UNC (rolled thread), Medium Carbon Steel (Grade 5 or better) with Zinc Plate and Dichromate finish. • All mounting hardware must be properly installed and torqued to the specifications listed. APPROXIMATE WEIGHTS Thermo King HK unit with EON battery installed. Thermo King recommends the fuel tank be centered directly under the HK heating unit. 28 Installing the Fuel Tank - Aluminum, L-Shaped, 65 Gallon - (Option) . 29 Installing the Fuel Tank - Aluminum, L-Shaped, 65 Gallon - (Option) Fuel Tank Installation 1. Install the tank mounting brackets with six, (installer supplied) 1/2-13 screws, washers and locking nuts onto the front wall. Torque the hardware to 81 to 88 N•m (60-65 ft-lb.). 2. Clean the inside surfaces of the mounting brackets and support straps. Install the 711 mm (28.00') long rubber strips onto the mounting brackets and the 635 mm (25.00'') long rubber strips onto the support straps. 3. Install and center the tank onto the mounting brackets. 4. Install the mounting straps with T-bolts onto the upper holes of the mounting bracket with the supplied 1/2'' washers and locking nuts. Verify the rubber strips are properly installed on the mounting straps and straps are aligned with the strap guides on the top of the tank. Leave the nuts finger-tight on the threads. 5. Install the support straps to the lower mounting holes of each mounting bracket with the supplied 1/2-13 x 1.50'' long bolts, flat washers and locking nuts. Leave the nuts finger-tight on the threads. 6. Tighten the lower nuts first to 44.5 N•m (33 ft-lb.) or until 2 full threads are exposed through the locking material of the nut, then tighten the upper nuts to 44.5 N•m (33 ft-lb.). NOTE: At least two full threads must be exposed after 44.5 N•m (33 ft-lb.) is applied. If not, tighten the nuts until two full threads project through the locking material of the nuts. IMPORTANT: Do not over tighten the mounting hardware or damage to the tank will result. 30 Installing the Fuel Tank - Aluminum, L-Shaped, 65 Gallon - (Option) Mounting Strap with T-bolts and Rubber Pad Mounting Bracket with 711 mm (28.00'') Rubber Pad Support Strap with 635 mm (25.00'') Rubber Pad St rap Gu ide s 31 Installing the Fuel Tank - Steel, Rectangle, 65 Gallon - (Option) Important Fuel Tank Installation Information NOTE: These instructions are written exclusively for, and are limited to, the installation of the 65 gallon steel fuel tank, positioned directly under a Thermo King HK heating unit, and mounted onto the front wall of a trailer or intermodal container designed specifically for this application. All other installations are the responsibilities of the installer. DANGER: An improperly installed fuel tank could lead to serious injury or death! The mounting hardware to secure the fuel tank and mounting brackets onto the front wall of the trailer or intermodal container is to be supplied by the installer and must be 1/2-13 UNC (rolled thread), Medium Carbon Steel (Grade 5 or better) with Zinc Plate and Dichromate finish. Additionally, the front wall of the trailer or intermodal container must be structurally strong enough to safely support the combined total weight of the HK heating unit, the fuel tank and mounting brackets and 65 gallons of diesel fuel (see chart below). Consult your trailer or intermodal container manufacturer for details regarding your specific installation. APPROXIMATE WEIGHTS Thermo King HK unit with EON battery installed. HK-430 HK-430 HO (203 kg) 448 lbs. 221 kg (488 lbs). Rectangle steel fuel tank, mounting brackets and hardware. 89.4 kg (197 lbs.) 89.4 kg (197 lbs.) 65 gallons of diesel fuel. 236 kg (520 lbs.) 236 kg (520 lbs.) COMBINED TOTAL WEIGHT 528 kg (1165 lbs.) A. FUEL TANK POSITION • Thermo King recommends the fuel tank be centered directly under the HK heating unit. B. TANK STRAP POSITION • L-brackets and support straps must be positioned 1225 mm (48.25 in.) apart to properly support the weight of the tank and fuel. C. RUBBER PADS AND STRIPS • Rubber pads and strips must be properly installed on the L-brackets and support straps to prevent metal to metal contact. D. MOUNTING HARDWARE • Grade 5 mounting hardware is supplied to secure the tank to the L- brackets. • Mounting hardware to secure the complete fuel tank and mounting t assembly onto the trailer or container is to be supplied by the installer and must be 1/2-13 UNC (rolled thread), Medium Carbon Steel (Grade 5 or better) with Zinc Plate and Dichromate finish. • All mounting hardware must be properly installed and torqued to the specifications listed. 547 kg (1205 lbs.) 32 Installing the Fuel Tank - Steel, Rectangle, 65 Gallon - (Option) 33 Installing the Fuel Tank - Steel, Rectangle, 65 Gallon - (Option) Fuel Tank Installation 1. Install the L-brackets with six, (installer supplied) 1/2-13 screws, washers and locking nuts onto the front wall of the container or trailer. Torque the hardware to 81 to 88 N•m (60-65 ft-lb.). 2. Clean the inside surfaces of the L-brackets and install the 710 mm (27.95 in.) self-adhesive rubber pads. Slide the 813 mm (32.00 in.) rubber strips onto the support straps. 3. Position and center the tank onto the L-brackets. 4. Install the T-bolts on the support straps into the upper and lower holes of the L-brackets with the supplied 1/2'' washers and locking nuts. Verify the rubber pads and strips are properly positioned on the Lbrackets and straps to prevent any metal to metal contact before hand tightening the mounting hardware. Leave the nuts finger-tight on the threads. 5. Tighten the lower nuts first to 44.5 N•m (33 ft-lb.) or until 2 full threads are exposed through the locking material of the nut, then tighten the upper nuts to 44.5 N•m (33 ft-lb.). NOTE: At least two full threads must be exposed after 44.5 N•m (33 ft-lb.) is applied. If not, tighten the nuts until two full threads project through the locking material of the nuts. IMPORTANT: Do not over tighten the mounting hardware or damage to the tank will result 34 Installing the Fuel Tank - Steel, Rectangle, 65 Gallon - (Option) 35 Installing the Fuel Pump and Fuel Lines FOR UNDER CHASSIS FUEL TANKS Installation Recommendations DANGER: Leaking fuel lines could cause a fire resulting in death or serious injury! All fuel line fittings must be tight and leak free! DANGER: Do not route fuel lines with battery cables or electrical wires, as this could cause a fire! • All fuel lines should be routed in a protective housing with no kinks and sharp bends. • Rubber grommets must be used when routing fuel lines through holes in metal. • Secure all fuel lines with provided clamps. • Remove plastic cap from the fuel vent and point the outlet towards the rear of the trailer. Installing the Fuel Pump and Fuel Lines 1. Install the fuel pump and bracket as low as possible to provide rapid pump priming. 2. Route the fuel supply line from the fuel filter located inside the unit, down to the fuel pump and then to the fuel pickup tube on the fuel tank. Install fuel line connectors (provided in installation kit), cut end of fuel line at a 45 degree angle and insert into fuel pickup tube until it is 38.1 mm (1.50 in.) from the bottom of the tank and tighten securely. 3. Route the fuel return line from the fuel filter located inside the unit down to the fuel tank return fitting. Attach fuel line connectors and tighten securely. 4. Route the electrical harness from the unit to the fuel pump and attach to the fuel pump connector. The connector must be installed out of road spray area. NOTE: Add sufficient amount of fuel (1/4 tank) to allow the unit to run for 8 to 12 hours during engine break-in and pre-delivery procedures. 36 Installing the Fuel Pump and Fuel Lines FOR UNDER CHASSIS FUEL TANKS FUEL FILTER LOCATED INSIDE UNIT FUEL PUMP LOCATED OUTSIDE TRAILER 37 Installing the Fuel Pump and Fuel Lines FOR NOSE MOUNTED L-SHAPED and RECTANGLE SHAPED 65 GALLON FUEL TANKS Fuel Pump Installation DANGER: Leaking fuel lines could cause a fire resulting in death or serious injury! All fuel line fittings must be tight and leak free! Fuel Line Installation 3. Remove the protective plugs from each of the fuel fittings and install the fuel line supply and return line fittings securely. 4. FUEL SUPPLY - Route fuel lines from: DANGER: Do not route fuel lines with battery cables or electrical wires, as this could cause a fire! • Supply fitting on the fuel filter to the top outlet fitting of the fuel pump. 1. Install the fuel pump and bracket inside the unit next to the battery box with 1/4-20 screws, flat washers and locking nuts. Tighten hardware securely. • Side inlet fitting on the fuel pump to the fuel tank fitting. • Tighten all fuel line fittings securely. 2. Route and attach the fuel pump harness to the fuel pump. 5. FUEL RETURN - Route fuel line from: • Return line fitting from the fuel filter to the fuel tank fitting. • Tighten all fuel line fittings securely. 6. Secure all fuel lines adequately with cable ties or clamps. 7. Remove the plastic cap from the fuel vent and point it towards the rear of the unit. NOTE: Add sufficient amount of fuel (1/4 tank) to allow the unit to operate. 8. Operate the unit and check all fuel line fittings for leaks. 38 Installing the Fuel Pump and Fuel Lines FOR NOSE MOUNTED L-SHAPED and RECTANGLE SHAPED 65 GALLON FUEL TANKS FUEL PUMP LOCATED INSIDE HK UNIT FUEL FILTER LOCATED INSIDE UNIT Return Supply 39 Installing the Remote Status Light - (Option) Installation NOTE: Corner mounted light shown. Flush mounted light installs into recessed opening (See “Flush Mount Status Light Opening Dimensions (Option)” on page 17. 1. Mount the Status Light in a location that is visible in the tractor mirror to the driver. • Mark and drill the four mounting holes using a 3/16'' drill. • Mount the status light in position with the supplied rivets. 2. Route harness as shown allowing a “drip-loop” to prevent water from migrating into the Status Light. 3. Secure harness to the bracket and trailer using the supplied clamps and rivets. 4. Connecting the Status Light harness to the matching connector located inside the unit attached to the roadside engine mount. IMPORTANT: DO NOT secure excess harness to battery cables or electrical harnesses. 40 Installing the Remote Status Light - (Option) 41 Installing the Battery Installing the Battery CAUTION: Set all electrical controls to the OFF position before connecting the battery to prevent the unit from starting! 1. Open unit door to access battery tray. 2. Install battery into tray and secure with hold down bracket, bolts, lock washers and flat washers. • CAUTION: Always wear protective clothing, gloves and eye wear when handling and installing batteries! CAUTION: Cover battery terminals to prevent accidental shorting during battery installation! CAUTION: Do not route battery cables together with fuel lines as this could cause a fire! Hand tighten both bolts and then torque to 6.8 N•m (60 in-lb). DO NOT over tighten hardware as this may crack or distort the battery! 3. Install positive + battery cable on the positive battery post first to minimize accidental electrical shorting. 4. Install negative - battery cable on negative battery post second to minimize accidental electrical shorting. 5. Close and secure unit door. CAUTION: All battery connections must be clean and tightly secured. 42 Installing the Battery 43 SYSTEM CHECK LIST All unit mounting hardware torqued to specifications. Battery secured correctly and all connections clean and tight. No air gaps between unit and trailer wall. Remote HMI mounted securely. Drain hose properly routed and secured. Run Pre-Trip Inspection (refer to Operator’s Manual). Fuel tank properly installed. Run unit under load for eight hours to properly break-in engine. Fuel lines properly routed and fuel fittings tightened securely. Release to customer. Bulkhead properly designed and installed. 44 TK 55186-2-IM (Rev. 0, 09/11) Trailer Edition HK-430 and HK-430 HO Diesel Heating Units Installation Manual Providing equipment and services to manage controlled-temperature environments for food and other temperature-sensitive products, our Climate Control Technologies sector encompasses both transport and stationary refrigeration solutions. Our product brands include Thermo King®, a world leader in transport temperature control systems, and Hussmann®, a manufacturer of refrigeration and food merchandising equipment. www.thermoking.com ©2008 Ingersoll-Rand Company Printed in U.S.A. on Recycled Paper www.hussmann.com www.ingersollrand.com